Method and Assembly for Repairing Plasterboard Walls and Ceilings

ABSTRACT

A plasterboard wall or ceiling repair assembly for repairing a hole in a plasterboard wall or ceiling panel, the assembly comprising: a sheet adapted to be deformed and passed through the hole of the plasterboard wall to be positioned for engagement with an inner or non-exposed surface of the plasterboard wall surrounding said hole; and an inflatable balloon coupled with the sheet for retaining the sheet in engagement with the inner non-exposed surface of the plasterboard wall.

TECHNICAL FIELD

The present invention relates to repair materials and more particularly to a plasterboard wall repair assembly and a method for repairing a damaged plasterboard wall and/or ceiling.

BACKGROUND

Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

There has long been a long felt need for inexpensive wall repair systems, which are relatively easy to use so that unskilled people are able to carry out minor repairs on damaged plasterboard walls. Various wall or surface repair systems that utilize a repair patch have been proposed as an option for repairing damaged portions of surfaces, such as holes in drywall material. These repair patches are designed so as to reinforce and position the curable repair materials, such as plaster or polymeric materials, that are applied to the surface being repaired.

While some of these known repair patches have produced satisfactory results one of the problems with currently known patches is that they are placed above the exposed surface of the damaged region which generally results in a non-planar finish on the repaired wall. Moreover, these known repair patches are not well suited for repairs to non-planar, contoured structures have been rendered difficult because of the inability to form a correctly contoured matching surface for holding, positioning and reinforcing the repair materials. For instance, certain repair patches include a rigid plate which is formed from a metallic material. This type of repair patch cannot be deformed freely in all directions because the rigid plate is often formed from metal strip of a relatively thick gauge. In addition, certain grades of metallic strip or sheet which are used to form the rigid plate of the repair patch may be much more difficult to bend in certain directions.

In view of the shortcomings of the prior art repairing methods and systems, it is desirable to provide an inexpensive and relatively uncomplicated plasterboard wall repair assembly patch for applying on the surface of an interior wall made from plasterboard having a hole therein to be repaired.

SUMMARY OF INVENTION

In one aspect, the invention provides a plasterboard wall or ceiling repair assembly for repairing a hole in a plasterboard wall or ceiling panel, the assembly comprising:

a sheet adapted to be positioned for engagement with an inner or non-exposed surface of the plasterboard wall or ceiling panel surrounding said hole, said sheet being configured to receive a curable compound on an outwardly facing surface;

an inflatable balloon coupled with the sheet for retaining the flexible sheet in engagement with the inner non-exposed surface of the plasterboard wall or ceiling panel.

In an embodiment, the sheet is a flexible sheet adapted to be deformed and passed through the hole of the plasterboard wall or ceiling panel to be positioned for engagement with the inner or non-exposed surface of the plasterboard wall or ceiling panel surrounding said hole.

In an embodiment, the inflatable balloon comprises an inflation lumen positioned relative to the sheet to allow inflation of the balloon after positioning the sheet in engagement with the inner surface of the plasterboard wall or ceiling.

In an embodiment, the balloon defines an inflation cavity such that fluid conveyed through the inflation lumen into the inflation cavity inflates or deflates the balloon.

In an embodiment, the inflation cavity is sufficiently large such that, upon being inflated, outer walls of the inflated balloon abut an inner surface of the sheet and one or more panels and/or one or more structural members positioned behind the plasterboard wall.

In an embodiment, the sheet comprises an opening for receiving and retaining the inflation lumen of the balloon.

In an embodiment, in an inflated configuration, the balloon is adapted to be attached to the sheet during use.

In an embodiment, the inflation lumen is adapted to remain attached to the sheet. In an embodiment, the sheet is perforated and formed from a plastically deformable polymeric material.

In an embodiment, the perforations are sized for receiving and supporting a curable compound thereon.

In an embodiment, the sheet comprises a relatively thickened portion flanked by relatively thinner portions of the sheet for allowing said thinner portions to flex relative to the thickened portion.

In an embodiment, the thickened portion extends across the flexible sheet to allow the thinner portions to flex relative to the diagonally oriented thickened portion.

In an embodiment, the sheet is substantially rectangular.

In an embodiment, surface area of the sheet is sufficiently large to cover the hole upon being placed in engagement with the inner surface of the plasterboard wall or ceiling surrounding the hole.

In an embodiment, the flexible sheet is deformable to conform to the contour of the inner surface of the plasterboard wall or ceiling.

In an embodiment, the assembly further comprises the curable compound for being applied on the flexible sheet and covering the hole when the flexible sheet is retained against the inner surface of plasterboard wall or ceiling by the inflated balloon.

In an embodiment, the plasterboard wall or ceiling repair assembly in accordance with any one of the preceding claims further comprising a flexible cradle, the cradle member comprising: end portions for being attached to the inner surface of the wall or ceiling panel surrounding the hole with one or more cradle body members being structured to be positioned relative to the flexible sheet during use to accommodate the inflated balloon therebetween and apply a pushing force on the inflated balloon to push the flexible sheet into engagement with the inner surface of said wall or ceiling panel.

In an embodiment, the end portions of the cradle body members are attached to the inner surface of the wall or ceiling panel surrounding the hole.

In an embodiment, the cradle body members comprises one or more elongate flexible members that intersect each other and extend across the hole to receive and support the inflated balloon during use.

In an embodiment, the cradle body members comprise substantially thin and flexible polymeric materials.

In another aspect, the invention provides a method of repairing a hole in a plasterboard wall panel, the method comprising the steps of:

passing a flexible sheet through the hole and positioning said sheet for engagement with an inner and/or non-exposed surface of the plasterboard wall surrounding said hole and positioning the sheet across the hole to cover the hole;

inflating a balloon attached to said flexible sheet by supplying fluid into said balloon such that outer walls of the inflated balloon abut an inner surface of the flexible sheet and one or more panels and/or one or more structural members positioned behind the plasterboard wall thereby retaining the flexible sheet across the hole; and applying a curable compound on an outer exposed surface of the flexible sheet and covering said exposed surface with the curable compound;

contouring the curable compound to the shape of the outer surface of the plasterboard; and

allowing the curable compound to cure.

In another aspect, the invention provides a method of repairing a hole in a plasterboard ceiling panel, the method comprising the steps of:

passing a flexible cradle through the hole and positioning the cradle across the hole with end portions of the cradle being attached to an inner/non-exposed surface of the ceiling panel surrounding the hole;

passing a flexible sheet through the hole and positioning said sheet for engagement with the inner and/or non-exposed surface of the plasterboard wall surrounding said hole and positioning the sheet across the hole to cover the hole;

inflating a balloon attached to said flexible sheet by supplying fluid into said balloon such that outer walls of the inflated balloon abut an inner surface of the flexible sheet and the cradle positioned behind said flexible sheet thereby retaining the flexible sheet across the hole;

applying a curable compound on an outer exposed surface of the flexible sheet and covering said exposed surface with the curable compound;

contouring the curable compound to the shape of the outer surface of the plasterboard; and

allowing the curable compound to cure.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

FIG. 1 is a frontal view of a damaged portion (with a hole H) of a plasterboard wall W.

FIG. 2 is a perspective view of the damaged portion (with a hole H) of a plasterboard wall W.

FIG. 3 is a frontal view of a plasterboard wall repair assembly 100.

FIG. 4 is a first frontal perspective view of the plasterboard wall repair assembly 100 shown in an in-use configuration whereby the user bends or flexes the flexible sheet 110 to insert the sheet 110 into the hole H.

FIG. 5 is a second frontal perspective view of the plasterboard wall repair assembly 100 shown in an in-use configuration whereby the user bends or flexes the flexible sheet 110 to insert the sheet 110 into the hole H.

FIG. 6 is a third frontal perspective view of the plasterboard wall repair assembly 100 shown in an in-use configuration whereby the flexible sheet 110 has been inserted into the hole H and is being positioned against an inner surface of the wall W by pulling the inflation lumen 125 of the balloon 120 attached to the flexible sheet 110 via the opening 116.

FIG. 7 is a sectional view of the plasterboard wall repair assembly 100 including the position of the balloon 120 in relation to the flexible sheet 110 (shown in an inserted position) as positioned between the plasterboard panel W and rear panel R.

FIG. 8 is a sectional view of the plasterboard wall repair assembly 100 showing the balloon 120 in a fully inflated configuration.

FIG. 9 is a sectional view of the plasterboard wall repair assembly 100 showing the balloon 120 in a fully expanded position whereby the inflation lumen 125 has been closed or sealed using a knot.

FIG. 10 is a sectional view of the plasterboard wall repair assembly 100 showing the application of a curable compound 140 within the hole H whilst the flexible sheet 110 is held in position by the expanded and sealed balloon 120.

FIG. 11 is a sectional view of the plasterboard wall assembly 100 wherein the curable compound 140 is contoured to become level with the exposed surface of the plasterboard wall W.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1 to 2 illustrate frontal and perspective views of a damaged portion of a plasterboard wall W which includes a hole H that is to be repaired using the plasterboard wall repair assembly 100 in accordance with an embodiment of the present invention.

Referring now to FIGS. 3-11, there is shown a plasterboard wall repair assembly generally designated as 100. The plasterboard wall repair assembly 100 includes a contourable sheet 110 that is rectangular in shape. The shape of the sheet 110 is in no way limited and any other regular or non-regular shaped sheets may be used without departing from the scope of the presently described invention. The sheet 110 has a first side 112 and a second side 114 (shown clearly in FIGS. 7 to 11) and includes a plurality of small perforations 117 that help support a curable compound thereon and assist with repairing a hole (such as hole H) in a damaged portion of a plasterboard wall W shown in FIGS. 1 and 2 by being positioned in engagement with an inner or non-exposed surface of the damaged plasterboard wall panel that surrounds the hole H.

The flexible sheet 110 is coupled with an inflatable balloon 120 that assists with retaining the flexible sheet 110 in position (specifically in engagement with the inner surface of the plasterboard wall that surround the hole H) in an inflated configuration while the curable compound is applied on the second side 114 of the flexible sheet 110. As is clearly evident from the drawings, the flexible sheet 110 includes a centrally disposed opening 116 in which an inflation lumen 125 of the balloon 120 is received and engaged.

The use of the plasterboard wall repair assembly 100 involves flexing the flexible sheet 110 and passing the flexed sheet 110 through the hole H (best shown in FIGS. 4 and 5). In the preferred embodiment, the flexible sheet 110 includes a thickened region 115 that extends midway through the sheet 110 and is flanked by two flexible sections 123 which can be flexed to aid with insertion of the flexible sheet 110. The flexible sheet 110 is formed from a plastically deformable inelastic polymeric material. As used throughout the specification and claims, a deformable elastic material refers to a material that will deform on applying a deforming force and may either completely or at least partially return to its original shape when the applied force is removed. In this instance, the user has to apply a force to pull the flexible portions towards each other to effectively fold the sheet 110 along the thickened region 115 thereby reducing the overall width of the flexible sheet 110 which in turn allows the sheet 110 to be inserted through the hole H. Once the sheet 110 has been inserted into the hole H, the force is no longer applied, the sheet 110 may return back from its folded configuration to its original flat configuration. Suitable deformable elastic polymeric materials used to form the sheet 110 include polyolefins, such as polyethylene and polypropylene, polyvinyl resins, and copolymers and mixtures thereof. Polyvinyl resins that are deformable, such as polyvinyl butyral resins or polyvinyl chloride may also be used for forming the sheet 110.

The polymeric material may also be blended with a filler selected from the group consisting of metal carbonates, metal silicates, metal oxides, glass fibres, wood sawdust, and wood flour. The filler may serve to increase the rigidity of the polymeric material and may even lower the cost of forming the sheet. The rigidity of the polymeric material may also be increased by increasing the density of the polymeric material used to form the sheet 110.

Once the sheet 110 has been inserted, the flexible sheet 110 is positioned to lie flat against the inner surface of the plasterboard wall panel. Advantageously, the inserted sheet 110 can be pushed against the inner surface of the plasterboard wall panel by pulling the inflation lumen 125 of the balloon 120 that extends out from the second surface 114 of the flexible sheet 110. The centrally disposed opening 116 in the sheet 110 is suitably sized to be smaller than the inflation cavity of the balloon 120 to prevent the balloon 120 from being inadvertently uncoupled from the flexible sheet 110 when the inflation lumen 125 is being pulled to position the flexible sheet 110 against the inner surface around the hole of the plasterboard wall panel.

The next step for repairing the hole H in the damaged portion of the plasterboard wall panel involves supplying air (or any other fluid) into the balloon 120 through the inflation lumen 125. The balloon 120 may be blown up by the person carrying out the repairs by simply blowing into the inflation lumen 125 of the balloon 120. Other suitable methods for supplying fluid including an air pump may also be used to blow up the balloon 120. As fluid is supplied into the inflation cavity of the balloon 120, the volume of the inflation cavity progressively increases and becomes sufficiently large to abut the first surface (the inner surface) of the flexible sheet 110 (See sectional views in FIGS. 7 to 11) and one or more building panels or structural members positioned behind the damaged plasterboard wall panel. In FIGS. 7 to 11, R denotes a rearwardly located building which can be any building panel including but not limited to a plasterboard wall panel (for an internal wall assembly) or a cladding panel (for an external wall assembly). Once the inflation volume of the balloon 120 has been fully expanded (See FIG. 8), the inflation lumen may be closed or sealed by any suitable means (See FIG. 9). In the presently described embodiment, the inflation lumen may be sealed by suitably tying up the end of the inflation lumen 125 to prevent any fluid from escaping the inflation volume of the balloon 120.

Referring to FIGS. 8 to 11, it is clear that in a fully expanded configuration, the balloon 120 supports the flexible sheet 110 and retains the flexible sheet 110 in position. In fact, the walls of the balloon 120 apply a pressing force on the flexible sheet 110 by pushing the flexible sheet 110 against the inner surface surrounding the hole of the damaged plasterboard wall. It is also important to note that the dimensions of the flexible sheet 110 should be ideally greater than the size of the hole H so that the flexible sheet 110 can be pressed against the inner surface of the plasterboard wall that surrounds the hole H.

Once the flexible sheet 110 is pressed into position by the inflated balloon 120, the next repairing step involves applying a curable compound 140 such as plaster of paris, gypsum material, spackling compound, joint compound, fiberglass resin compound, spackle or other curable repair compound 140 which completes the assembly. It can be seen that the curable compound 140 is applied on the second surface 114 (or the outer surface) which faces outwardly and is positioned across the hole H. The curable compound 140 is received on the perforations of the flexible sheet 110 and spread evenly over the flexible sheet 110 (See FIG. 10) to fill up the volume between the second surface 114 of the flexible sheet 110 and the outer surface of the plasterboard wall. The applied curable compound 140 may be contoured (shown in FIG. 11) to become suitably level with the visible or exposed surface of the plasterboard wall panel. As with all curable compounds, once the contouring step has been carried, the contoured compound may be left to be cured for a specified time period (depending on the characteristics of the curable compound 140). Of course, other methods such as application of heat or other types of suitable radiation may also be applied to aid curing of the contoured compound 140.

There are several advantages presented by the plasterboard wall or ceiling repair assembly 100. First, positioning the flexible sheet 110 along an inner surface of the plasterboard panel allows the curing compound 140 to be spread evenly over the flexible sheet and be contoured to become level with the outer exposed surface of the plasterboard wall panel W. The provision of the inflated balloon 120 pressing against the flexible sheet 110 allows the repairer to apply the curable compound to be applied and pressed against the outer second surface 114 of the flexible sheet 110 without the flexible sheet 110 falling into the cavity between the wall panels. Another advantage is that the inflated balloon 120 fills up the space or cavity in between the plasterboard panel W and the rear panel R regardless of the exact spacing between these panels. Even if the outer plasterboard panel W is curved, the inflated balloon 120 applies an even pressing force against the flexible sheet 110 to be pushed against the curved inner surface of the plasterboard W thereby allowing repair of curved plastered panel surfaces.

Referring to FIGS. 12 and 13, the plasterboard wall repair assembly 100 may also be useful to repairing plasterboard ceiling panels (designed by C in FIG. 13). Unlike plasterboard wall panels (such as panels W, as described in the previous sections), ceiling panels may not have any structural panels or members positioned behind the ceiling panel for pushing against the inflated balloon 120. A flexible cradle 170 may therefore be provided to support the inflated balloon 120 and help push the inflated balloon 120 against the flexible sheet 110. A plan view of the flexible cradle 170 is shown in FIG. 12. The cradle 170 includes two elongate and flexible cradle body members 174 that intersect each other and are mutually perpendicular. It must be understood that the number of flexible cradle body members 174 is not limiting and a plurality of such cradle body members 174 may be used for forming the cradle 170. End portions of the cradle body members are provided with a fastening arrangement in the form of adhesive patches 172 to allow end portions of the cradle body members 174 to be attached to the inner surface of the ceiling panel C surrounding the hole H. Typical installation of the cradle 170 would involve insertion of the flexible cradle 170 through the hole H by folding the flexible body members 174 before unfolding the cradle members 174 for attachment of the cradle members 174 across the hole H (best shown in FIG. 13).

The next ceiling hole repairing step involves insertion of the flexible sheet 110 through the hole to be positioned in a spaced apart and forwardly position relative to the cradle 170 so that the balloon 120, in an expanded position, contacts the cradle members 170 and the cradle members 174 in turn push the balloon 120 towards the flexible sheet 110 which in turn is pressed against the inner surface of the ceiling panel C surrounding the hole H. It is also important to note that the length of the elongate cradle members 174 should be longer than the length of the flexible sheet 110 in order to accommodate the flexible sheet 110 between the end portions of the cradle members and allow the inflated balloon 120 to contact the cradle members 170. The cradle members 174 may be made from flexible and strong materials including but not limited to: paper, plastic, laminates or Tyvek®.

In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features.

It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art. 

What is claimed:
 1. A plasterboard wall or ceiling repair assembly for repairing a hole in a plasterboard wall or ceiling panel, the assembly comprising: a sheet adapted to be positioned for engagement with an inner or non-exposed surface of the plasterboard wall or ceiling panel surrounding said hole, said sheet being configured to receive a curable compound on an outwardly facing surface; an inflatable balloon coupled with the sheet such that, upon being inflated, outer walls of the inflated balloon abut an inner surface of the sheet for retaining the sheet in engagement with the inner non-exposed surface of the plasterboard wall or ceiling panel, wherein the inflatable balloon comprises an inflation lumen attached to the sheet in a deflated configuration to prevent uncoupling of the deflated balloon relative to the sheet and allow inflation of the balloon after positioning the sheet in engagement with the inner surface of the plasterboard wall or ceiling.
 2. A plasterboard wall or ceiling repair assembly in accordance with claim 1 wherein the sheet is a flexible sheet adapted to be deformed and passed through the hole of the plasterboard wall or ceiling panel to be positioned for engagement with the inner or nonexposed surface of the plasterboard wall or ceiling panel surrounding said hole.
 3. A plasterboard wall repair assembly in accordance with claim 1 wherein the balloon defines an inflation cavity such that fluid conveyed through the inflation lumen into the inflation cavity inflates or deflates the balloon.
 4. A plasterboard wall repair assembly in accordance with claim 3 wherein the inflation cavity is sufficiently large such that, upon being inflated, outer walls of the inflated balloon abut the inner surface of the sheet and one or more panels and/or one or more structural members positioned behind the plasterboard wall.
 5. A plasterboard wall repair assembly in accordance with claim 1 wherein the sheet comprises an opening for receiving and retaining the inflation lumen of the balloon.
 6. A plasterboard wall repair assembly in accordance with claim 1 wherein in an inflated configuration, the balloon is adapted to be attached to the sheet during use.
 7. A plasterboard wall or ceiling repair assembly in accordance with claim 1 wherein the sheet is perforated and formed from a plastically deformable polymeric material.
 8. A plasterboard wall or ceiling repair assembly in accordance with claim 7 wherein the perforations are sized for receiving and supporting a curable compound thereon.
 9. A plasterboard wall or ceiling repair assembly in accordance with claim 1 wherein the sheet comprises a relatively thickened portion flanked by relatively thinner portions of the sheet for allowing said thinner portions to flex relative to the thickened portion.
 10. A plasterboard wall or ceiling repair assembly in accordance with claim 9 wherein the thickened portion extends diagonally across the sheet to allow the thinner portions to flex relative to the diagonally oriented thickened portion.
 11. A plasterboard wall or ceiling repair assembly in accordance with claim 1 wherein the sheet is substantially rectangular.
 12. A plasterboard wall or ceiling repair assembly in accordance with claim 1 wherein surface area of the sheet is sufficiently large to cover the hole upon being placed in engagement with the inner surface of the plasterboard wall or ceiling surrounding the hole.
 13. A plasterboard wall or ceiling repair assembly in accordance with claim 1 wherein the sheet is deformable to conform to a contour of the inner surface of the plasterboard wall or ceiling panel.
 14. A plasterboard wall or ceiling repair assembly in accordance with claim 1 further comprising a curable compound for being applied on the sheet and covering the hole when the sheet is retained against the inner surface of the plasterboard wall or ceiling panel by the inflated balloon.
 15. A plasterboard wall or ceiling repair assembly in accordance with claim 1 further comprising a flexible cradle, the cradle comprising one or more body members having end portions for being attached to the inner surface of the plasterboard wall or ceiling panel surrounding the hole with the one or more body members being structured to be positioned relative to the sheet to accommodate the inflated balloon therebetween and apply a pushing force on the inflated balloon to push the sheet into engagement with the inner surface of said wall or ceiling panel.
 16. A plasterboard wall or ceiling repair assembly in accordance with claim 15 wherein the end portions of the cradle body members are attached to the inner surface of the wall or ceiling panel surrounding the hole.
 17. A plasterboard wall or ceiling repair assembly in accordance with claim 15 wherein the cradle body members comprises one or more elongate flexible members that intersect each other and extend across the hole to receive and support the inflated balloon.
 18. A plasterboard wall or ceiling repair assembly in accordance with claim 15 wherein the cradle body members comprise substantially thin and flexible polymeric materials.
 19. A method of repairing a hole in a plasterboard wall panel, the method comprising the steps of: passing a sheet through the hole and positioning said sheet for engagement with an inner and/or non-exposed surface of the plasterboard wall surrounding said hole and positioning the sheet across the hole to cover the hole; inflating a balloon attached to said sheet by supplying fluid into said balloon such that outer walls of the inflated balloon abut an inner surface of the sheet and one or more panels and/or one or more structural members positioned behind the plasterboard wall thereby retaining the sheet across the hole; and applying a curable compound on an outer exposed surface of the sheet and covering said exposed surface with the curable compound; contouring the curable compound to the shape of the outer surface of the plasterboard; and allowing the curable compound to cure.
 20. A method of repairing a hole in a plasterboard ceiling panel, the method comprising the steps of: passing a flexible cradle through the hole and positioning the cradle across the hole with end portions of the cradle being attached to an inner/non-exposed surface of the ceiling panel surrounding the hole; passing a sheet through the hole and positioning said sheet for engagement with the inner and/or non-exposed surface of the plasterboard ceiling panel surrounding said hole and positioning the sheet across the hole to cover the hole; inflating a balloon attached to said sheet by supplying fluid into said balloon such that outer walls of the inflated balloon abut an inner surface of the sheet and the cradle positioned behind said sheet thereby retaining the sheet across the hole; applying a curable compound on an outer exposed surface of the sheet and covering said exposed surface with the curable compound; contouring the curable compound to the shape of the outer surface of the plasterboard; and allowing the curable compound to cure. 